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Copyright © 2012 Boeing. All rights reserved.
The statements contained herein are based on good faith assumptions and provided for general information purposes only.
These statements do not constitute an offer, promise, warranty or guarantee of performance. Actual results may vary
depending on certain events or conditions. This document should not be used or relied upon for any purpose other than
that intended by Boeing.
Lithium Battery Cargo Awareness
D. Noe
Technical Lead Engineer
Cargo Systems Engineering
November 14, 2012
COPYRIGHT © 2012 THE BOEING COMPANY
Lithium Battery Introduction The term “lithium battery” refers to a family of batteries having cathodes or electrolytes
that contain either metallic lithium or a lithium compound
Lithium batteries are generally divided into two categories:
Lithium Metal Batteries
Lithium metal (primary)
batteries are non-rechargeable.
They feature higher energy
density than other older non-
rechargeable battery
chemistries
They are frequently used to
power cameras, watches,
medical devices (including
implantable devices), etc.
Lithium-Ion Batteries
Lithium ion (secondary)
batteries are rechargeable.
They feature a relatively high
energy density, and a
relatively slow loss of charge
when not in use.
Lithium ion batteries are
frequently used in consumer
electronics (mobile
telephones, laptop computers,
etc)
Included within the lithium ion
battery category are lithium
polymer batteries (sometimes
referred to as “pouch cells”)
Notebook
Battery that
Uses 18650
Cells
COPYRIGHT © 2012 THE BOEING COMPANY
Energetic failures (fire and/or explosion) of lithium type cells can occur for a number of reasons including:
Poor cell design (electrochemical or mechanical)
Cell manufacturing flaws
External abuse of cells (thermal, mechanical, or electrical)
Poor battery pack design or application
Poor protection electronics design or manufacture
Poor charger/system design or manufacture resulting in Overcharging of battery
Another failure is Cell thermal runaway, which is a rapid self-heating of a cell due to the exothermic chemical reaction of the highly oxidizing positive electrode and the highly reducing negative electrode.
Causes of Energetic Lithium Battery Failures
COPYRIGHT © 2012 THE BOEING COMPANY
Lithium Battery Cargo Shipment
Size and frequency of lithium battery air cargo shipments
continues to increase driven by growth in demand for consumer
and industrial goods powered by lithium batteries.
Concern about lithium battery cargo fires has led FAA William A.
Hughes Technical Center to conduct battery fire tests with the
following key findings: A relatively small fire source can ignite lithium ion or lithium metal cells
Fire from one cell will ignite adjacent cells in a bulk shipment of batteries
Energetic failure of lithium cells often creates a pressure pulse which
may damage fire-resistant cargo compartment liners and/or compromise
their decompression features
Halon fire suppressant is effective on lithium ion electrolyte fires, but will
not prevent the propagation of thermal runaway through bulk shipments
of batteries
Halon does not suppress lithium metal battery fires
Failed lithium metal batteries can eject molten lithium which may damage
cargo compartment liners
Metal pails and drums recommended by the ICAO are not effective in
controlling lithium metal cell fires, but are effective in containing lithium-
ion cell fires
Containers designed to ship oxygen generators can contain a 100-cell
lithium-ion cell fire
Typical Li-Ion Battery Cells Packed for Shipment
COPYRIGHT © 2012 THE BOEING COMPANY
Lithium Battery Transport Regulations
Air transport of lithium batteries is controlled by international and local regulations
governing the transport of dangerous goods (also referred to as hazardous material
regulations)
Most countries follow the ICAO Technical Instructions for the Safe Transport of
Dangerous Goods by Air but many also have local variations contained in their own
regulations
An example of local variations are United States 49 CFR Parts 171-180
administered by the Department of Transportation Pipeline and Hazardous Materials
Safety Administration (PHMSA)
A significant US local variation is that lithium metal batteries packed alone are prohibited
from being transported on passenger airplanes
Some airlines also have their own policies for transporting specific types of
dangerous goods (known as airline variations)
Many airlines, freight forwarders, and shippers use the IATA Dangerous Goods
Regulations as the working reference for dangerous goods transport requirements
because it includes the ICAO Technical Instructions, local variations, airline
variations, and additional requirements agreed to by IATA-member airlines to reflect
operational considerations
COPYRIGHT © 2012 THE BOEING COMPANY
Lithium Battery Transport Regulations – Recent Developments
ICAO regulation changes
New ICAO lithium battery air cargo transport regulations become effective January 1,
2013
New intermediate category introduced which increases control over battery/cell
shipments; however, relief still provided from fully regulated Class 9 shipment
requirements
DOT Pipeline and Hazardous Materials Safety Administration (PHMSA)
harmonizing US rules with ICAO standards as required by FAA reauthorization
act (HR 658) signed into law on February 14, 2011
DOT not allowed to implement further lithium battery shipping regulations without
credible evidence that lithium batteries transported in accordance with the
requirements of the ICAO Technical Instructions, have substantially contributed to the
initiation or propagation of an onboard fire
HR 658 further requires that US regulations conform only to ICAO standards with the
exception that the DOT may enforce the existing prohibition on transporting lithium
metal batteries aboard passenger aircraft
COPYRIGHT © 2012 THE BOEING COMPANY
Aviation-Related Lithium Battery Incidents
Recent cargo and baggage incidents that the FAA is aware of from
BATTERIES & BATTERY-POWERED DEVICES
Aviation Incidents Involving Smoke, Fire, Extreme Heat or Explosion
As of October 9, 2012, 132 air incidents involving batteries have been
recorded since March 20, 1991
61 total incidents are listed where Lithium Batteries were directly involved, resulting
in heat, smoke, fire or explosion
2 of the 61 incidents were direct result of mishandling of the package containing
the Lithium Batteries, and were not used for evaluation
Remaining 59 incidents were sorted by year of occurrence and categorized for:
Airplane Type – Cargo or Passenger
When incident occurred – boarding, in-flight, before loading or after transport
Battery Location – equipment, ULD, package, carry-on or checked bag
Where incident occurred – vehicle, onboard, ramp, facility or terminal
COPYRIGHT © 2012 THE BOEING COMPANY
Aviation-Related Lithium Battery Incidents
COPYRIGHT © 2012 THE BOEING COMPANY
Aviation-Related Lithium Battery Incidents
COPYRIGHT © 2012 THE BOEING COMPANY
Boeing Multi-Operator Message
Boeing released MOM-MOM-12-0356-01B (dated 22 May 2012) to share
regulatory and guidance information for lithium battery cargo transport
Boeing supports recommendations made by the FAA in the Safety Alert for Operators
(SAFO) 10017, dated 10/8/10, for transport of lithium batteries:
1) Request customers identify bulk shipments of currently excepted lithium batteries by information
on air waybills and other documents provided by shippers offering shipments of lithium batteries
2) Where feasible and appropriate, stow bulk shipments of lithium batteries in Class C cargo
compartments or in locations where alternative fire suppression is available
3) Evaluate the training, stowage, and communication protocols in your operation with respect to the
transportation of lithium batteries in the event of an unrelated fire
4) Pay special attention to ensuring careful handling and compliance with existing regulations
covering the air transportation of Class 9 hazardous materials, including lithium batteries
Additional Guidance can be found in:
– EASA Safety Information Bulletin (SIB) No. 2010-30R1, dated 31 March 2011
– ICAO Electronic Bulletin (EB) No. 2011/7, dated 15 February 2011
– IATA Website: www.iata.org/whatwedo/cargo/dangerous_goods/Pages/lithium_batteries.aspx
COPYRIGHT © 2012 THE BOEING COMPANY
Boeing Message to Operators
Boeing also provides the following non-mandatory suggestions to help minimize the
hazards associated with transporting lithium batteries as cargo:
1) Only accept lithium battery shipments that comply with applicable regulations (ICAO and/or local
regulations)
2) When possible, separate lithium battery shipments into smaller and separated groupings to
minimize the size of a potential battery fire
3) When possible, segregate lithium battery shipments from other dangerous goods that present a
fire hazard (e.g. Class 3 flammable liquid shipments) to minimize the effects of a lithium battery
fire and the potential for involving lithium batteries in adjacent cargo fire events
4) Consider establishing a policy to notify the flight crew of all lithium battery shipments (including
exempted shipments) so the flight crew is aware of the potential hazard
5) Implement methods or programs to increase your customer’s awareness of issues surrounding
the transport of lithium batteries. Items to consider might include:
Identifying customers who ship large volumes of lithium batteries
Creation of customer education materials to increase awareness around safely shipping lithium batteries
and to minimize undeclared battery shipments
Conducting compliance audits of high-risk shippers, high-volume shippers, high-risk product locations
Employee education regarding regulations, handling procedures, the dangers of mishandling, and methods
to identify lithium battery shipments
COPYRIGHT © 2012 THE BOEING COMPANY
Boeing Message to Operators
6) Take precautions to avoid unrestrained or shifting cargo events that might cause damage to
shipments of lithium batteries by establishing and following procedures to ensure cargo is
properly secured within containerized/palletized cargo compartments, cargo unit load devices,
and bulk cargo compartments
When possible, avoid loading lithium batteries in loosely-packed bulk cargo compartments to minimize the
potential for damage to the lithium batteries from shifting, or by the shifting of other cargo within the bulk
compartment, unless the cargo in the compartment is restrained against movement
7) Transporting bulk shipments of lithium metal batteries to, from, or through the US on passenger
airplanes is forbidden by US Department of Transportation (DOT) regulations. In accordance with
these regulations, consider eliminating bulk shipments of lithium metal batteries on passenger
airplanes
8) The fire resistant cargo lining systems of airplane cargo compartments are an integral part of the
overall cargo compartment fire protection system. Operators are reminded that airplane Master
Minimum Equipment Lists (MMEL) and Dispatch Deviations Guides (DDG) do not allow cargo
(except for ballast) to be transported in cargo compartments that have missing or damaged cargo
compartment liners
COPYRIGHT © 2012 THE BOEING COMPANY
Boeing Supports Industry Initiatives
Boeing is supportive of lithium battery fire testing, including testing by the NTSB and
the FAA Tech Center
Boeing is aware of ongoing development of shipping containers and fire containment
covers to facilitate the safe shipment of lithium batteries as cargo
Boeing will continue working with ICAO, government agencies and operators to
develop and share information and guidance to promote safe air transport of lithium
batteries
COPYRIGHT © 2012 THE BOEING COMPANY
Recommendations Going Forward
An overall solution which reduces the risks associated with transport of lithium
batteries will likely require concerted efforts by an industry forum consisting of airlines,
airplane manufacturers, regulatory agencies, battery producers, package
manufacturers, shippers, freight forwarders, ULD and equipment manufacturers, and
other involved parties
Suggest industry forum be led by DOT (FAA), since FAA Tech Center testing on
FCCs, FRCs, and 727 vehicle will be focus of industry attention
COPYRIGHT © 2012 THE BOEING COMPANY
Questions
D. Noe
Technical Lead Engineer
Cargo System Engineering
425-342-0727